Saddle Vehicle Shroud Rib Sink Mark Prevention
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Solution Overview
Problem
Existing saddle-type vehicle exterior covers with ribs for radiator shrouds suffer from sink marks due to thick material at the rib base, leading to a worsened external appearance.
Innovation Solution
The exterior cover is formed by integrating multiple resin members through insert molding or multi-color molding, where a first resin member constitutes the external-appearance surface and a second resin member with a rib on the non-external-appearance surface overlaps, hiding the sink mark and allowing the rib to be enlarged for enhanced rigidity and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the material thickness at the base portion of the rib is increased to enhance rigidity and structural strength, then the rib can serve as an effective reinforcement member and contact seat, but a sink mark is generated in the external-appearance surface, worsening the external appearance
Solution Approach 1:
The exterior cover is divided into multiple resin members (first resin member for external appearance, second resin member for structural function). The rib is formed only in the second resin member, separating the aesthetic requirement from the structural requirement. This allows the rib to provide reinforcement without compromising the external appearance surface.
Solution Approach 2:
The solution moves the rib structure to a different dimensional space - specifically to the non-external-appearance surface side. By positioning the rib in the second resin member that does not form the external appearance surface, the structural function is achieved without affecting the aesthetic dimension.
2Stability of the object's composition
If the rib height and material thickness are increased to utilize the rib as a reinforcement member, then the structural integrity is improved, but the material thickness at the base portion increases, causing sink marks
Solution Approach 1:
The exterior cover is segmented into multiple resin members with distinct functions. The second resin member contains the rib structure for structural integrity, while the first resin member provides the high-quality external appearance surface. This segmentation allows independent optimization of each component without compromise.
Solution Approach 2:
The first resin member acts as an intermediary that covers and protects the second resin member containing the rib. This intermediary layer prevents the sink marks in the rib base portion from being visible on the external appearance surface, thereby maintaining both structural integrity and surface quality.
3Stress or pressure
If the rib is enlarged to enhance the rigidity of the exterior cover, then the rigidity is improved, but the material thickness increases, leading to sink mark generation
Solution Approach 1:
The exterior cover is divided into multiple resin members, with the rib structure located exclusively in the second resin member. This segmentation enables the rib to be enlarged for enhanced rigidity without affecting the manufacturing quality of the external appearance surface formed by the first resin member.
Solution Approach 2:
Different regions of the exterior cover are assigned different qualities and functions. The second resin member region is optimized for structural performance with enlarged ribs, while the first resin member region is optimized for aesthetic appearance. This local differentiation allows rib enlargement without compromising manufacturing quality.
Data Source
AI summary
An exterior cover (shroud) for a saddle-type vehicle is formed by integrally uniting a plurality of resin members including a front cover section and a rear cover section. The shroud is insert molded to form an overlapping part where the front cover section and the rear cover section overlap with each other. The front cover section has an external-appearance-surface side at the overlapping part. The rear cover section has a non-external-appearance-surface side, which overlaps with the front cover section at the overlapping part. The rear cover section has a rib extending on the non-external-appearance-surface side. Such exterior cover prevents a sink mark from being generated in the external appearance surface of the front cover section, and improves the external appearance of vehicle.